Siemens Vibration Guidelines Monitoring

Monitoring of
Machine Vibration
Variables with a
SIPLUS SM 1281
Condition
Monitoring System
Siemens
SIPLUS SM 1281, SIMATIC S7-1200 Industry
Online
https://support.industry.siemens.com/cs/ww/en/view/109480750 Support
Warranty and liability
Warranty and liability
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Monitoring of Vibration Variables with SM 1281

Entry ID: 109480750, V2.0, 10/2017 2
Table of Contents
Table of Contents
Warranty and liability ................................................................................................... 2

1 Introduction ........................................................................................................ 4
1.1 Overview............................................................................................... 4
1.2 Mode of operation ................................................................................ 5
1.2.1 Configuration ........................................................................................ 5
1.2.2 Monitoring mode ................................................................................... 6
1.2.3 Program overview ................................................................................ 8
1.3 Components used .............................................................................. 11
2 Engineering ...................................................................................................... 12
2.1 Hardware setup .................................................................................. 12
2.2 Configuration ...................................................................................... 13
2.2.1 Preparation ......................................................................................... 13
2.2.2 Installing the HSP ............................................................................... 14
2.2.3 Downloading the STEP 7 project into the CPU .................................. 15
2.2.4 Downloading the WinCC project into the HMI .................................... 17
2.3 Commissioning ................................................................................... 18
2.3.1 Measuring the normal operating condition of the machine ................ 18
2.3.2 Determining the warning and alarm limits .......................................... 18
2.4 Operation ............................................................................................ 21
2.4.1 Notes on setting parameters .............................................................. 21

2.4.2 Setting the static parameters ............................................................. 22
2.4.3 Setting dynamic parameters .............................................................. 23
2.4.4 Changing the operating mode ............................................................ 23
2.4.5 Reading measured values.................................................................. 24
2.4.6 Restoring parameters from the backup .............................................. 25
3 Valuable Information ....................................................................................... 26
3.1 Basic terms ......................................................................................... 26
3.2 Mechanical vibrations ......................................................................... 27
3.2.1 Meaning and significance of vibrations .............................................. 27
3.2.2 Causes of mechanical vibrations ....................................................... 28
3.3 Monitoring and diagnosing vibrations ................................................. 29
3.3.1 Measuring vibrations .......................................................................... 29
3.3.2 Overview of diagnostic procedures .................................................... 32
3.3.3 Vibration diagnosis by measuring characteristic values in the
time domain ........................................................................................ 33
3.3.4 Vibration diagnosis through frequency analysis ................................. 35
3.3.5 Standards ........................................................................................... 36
3.4 SIPLUS SM 1281 ............................................................................... 36
3.5 Library "SM1281_Library" .................................................................. 37
3.5.1 Overview............................................................................................. 38
3.5.2 Function block "SM1281_Module" ..................................................... 38
3.5.3 Function “SM1281_Channel” ............................................................. 39
3.5.4 Data block "SM1281_Status" ............................................................. 39
3.5.5 Data block "SM1281_Backup" ........................................................... 39
3.5.6 Data types .......................................................................................... 39
4 Appendix .......................................................................................................... 40
4.1 Service & support ............................................................................... 40
4.2 Links and literature ............................................................................. 41
4.3 Change documentation ...................................................................... 41

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1 Introduction
1 Introduction
1.1 Overview
To protect a machine efficiently against mechanical damage during operation and
detect such damages at an early stage, the machine has to be monitored
permanently.
Mechanical vibrations are crucial in this context. Vibrations are caused mainly by
centrifugal forces at rotating machine parts.
This can be due to:
 Unbalance
 Improper alignment of machine trains
 Bearing-related damage
 Transmission faults
 Magnetic, hydraulic and other function-related changing forces
In order to monitor mechanical components, SIEMENS provides the SIPLUS CMS

Condition Monitoring Systems. This monitoring system gives a permanent overview
of all machines and of the entire system. In line with preventive maintenance,
servicing activities can thus be planned more efficiently and carried out on
schedule.
After a prolonged period of uninterrupted operation, the documented trend curves

enable early detection of significant changes as a result of wear or other damage-
related causes.
Topics not covered by this application

This application example covers the configuration of the SIPLUS SM 1281
Condition Monitoring Systems and the monitoring and visualization of characteristic
values (RMS). This documentation does not cover the evaluation of the frequency
spectrum using the integrated web server.
This application example does not include any description of the following topics:
 Configuring the drive
 Vibration diagnosis through frequency analysis
 Operating the integrated web server
 Data exchange via FTP
Assumed knowledge
The following basic knowledge is assumed:
 SIMATIC controllers
 STEP 7 programming
 WinCC

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1.2 Mode of operation

1.2.1 Configuration
Monitoring is done via the SIPLUS CMS1200 Condition Monitoring System with the
SM 1281 module. Specifically developed for connection to the SIMATIC S7-1200,
the monitoring thus can be seamlessly integrated into the automation process.
The figure below shows a schematic overview of the most important components of
the solution:
Figure 1-1: Overview of components
1 2
6 7 8 9 10
Table 1-1: Legend for Figure 1-1

Designation
1. S7-1200 automation system
2. CMS module SM 1281
3. HMI to visualize and operate the CMS
4. Vibration sensor to acquire the vibration acceleration
5. Retro-reflective photoelectric sensor for speed sensing
6. Bearing at the shaft end
7. Load
8. Bearing at the shaft coupling
9. Motor
10. SINAMICS V90 drive

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1 Introduction
Vibration sensor
The SM 1281 uses a vibration sensor to monitor the vibrations at the shaft end
bearing.
When commissioning the machine, the status under normal operating conditions is
determined. From the characteristic values measured, the user defines the warning
and alarm limits and stores them in the SM 1281.
Figure 1-2: Vibration sensor
During operation, the vibrations at the machine are monitored permanently and the
status is reported to the user via an HMI. Warnings and alarms are generated if the
set limit values are exceeded.
1.2.2 Monitoring mode
In monitoring mode, all variables to be monitored are measured, calculated and

checked for the configured limits. When limits are violated, the corresponding
messages are generated and the parameterized response is executed. A function
block enables the control program to access the messages.
The measured variables are cyclically transmitted to the controller and recorded as
a trend curve in the SM 1281. The trend curves can be displayed via the integrated
web server.
Note This application example focuses on starting up the SM 1281 and its monitoring
mode. Additional operating modes can be found in the SM 1281 operating
instructions:
https://support.industry.siemens.com/cs/ww/en/view/109481490
Threshold monitoring
To monitor RMS characteristic values, you can define threshold and hysteresis
values. Threshold values are only applicable for warning and alarm limits per
characteristic value.
RMS monitoring
The SM 1281 enables the calculation of the characteristic values aRMS and vRMS:
 vRMS is calculated based on the RMS value of vibration velocity.
 aRMS is calculated based on the RMS value of vibration acceleration.
Hysteresis
For the monitoring of vRMS and aRMS, three successive values that exceed the
threshold must be present to trigger a warning or alarm. Accordingly, three

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1 Introduction
successive values that fall below the threshold (including the absolute value
hysteresis) must be present for the warning or alarm to disappear again.

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1 Introduction
1.2.3 Program overview
PLC
The library “SM1281_Library” of the SM 1281 signal module was used for this
application example. It contains program blocks and HMI text lists. The library
enables the functions of the SM 1281 to be integrated easily into the user's control
program. Blocks and data types which are part of the library carry the prefix
“SM1281” in their name. Further information on the library "SM1281_Library" can
be found in chapter 3.5.
The user program in this application example has a modular structure so that
further modules can be added easily.
Figure 1-3: Program overview
SM1281_
OB1 CMS
Module
SM1281_
Channel
SM1281_
Channel
SM1281_
PlcHmi
Channel
SM1281_
Channel
Prepare
CMSData
ForHMI
SINA_
Drive
SPEED
Prepare
DriveData
ForHMI

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Table 1-2: Explanation of the blocks

Block Explanation
CMS This function block calls all required blocks for a specific
SM 1281 module.
If you are using several modules, create further instances of
this function block.
SM1281_Module This function block is part of the "SM1281_Library" and is
intended for configuring, controlling and monitoring the
SM 1281 module.
SM1281_Channel This function block is part of the "SM1281_Library" and is
intended for configuring, controlling and monitoring a channel
of the SM 1281.
For each channel (vibration sensor) used, the function
"SM1281_Channel" is called. The example project is prepared
for the maximum number of channels for an SM 1281 module,
even if only one channel is enabled and evaluated.
PrepareCMSDataForHMI This function prepares the data of the SM 1281 for
visualization.
Drive This function block controls the SINAMICS V90 drive.
If you are using several drives, create further instances of this
function block.
PrepareDriveDataForHMI This function prepares the data of the drive for visualization.
PlcHmi This data block is used for data exchange between PLC and
HMI.

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HMI
The SM 1281 is configured, operated and monitored via an HMI. Visualization
consists of the following screens:
Table 1-3: Explanation of the screens

Screen Explanation
Overview This start screen shows the monitoring status of the SM 1281
and controls the drive.
Actual Values On this screen, you can view the actual values of the channels
and start the recording of raw data or fingerprints.
Backup On this screen, you can view and restore the parameters of
the module that have been stored as backup.
Maintenance On this screen, you can exchange data with the module via
FTP.
This function is not discussed in this application example.
Parameters On this screen, you can define the parameters of the module
and its channels.
To make sure that further modules can be added to the application example, the
following faceplates have been created in the project:
Table 1-4: Explanation of the faceplates

Faceplate Explanation
ChannelBackup This faceplate shows the parameters of a channel that have
been stored as backup.
ChannelParameters With this faceplate, you can define the parameters of a
channel.
ChannelStatus This faceplate shows the monitoring status of a channel.
ModuleBackup This faceplate shows the parameters of the module that have
been stored as backup.
ModuleOverview This faceplate shows on overview of the monitoring states of a
module.
ModuleParameters With this faceplate, you can define the parameters of the
module.

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1.3 Components used

Validity
This application is valid for
 STEP 7 as of V13 SP1 Upd6
 WinCC as of V13 SP1 Upd6
 S7-1200 as of FW 4.1
 SM 1281 as of FW 2.0
Components used
This application example has been created with the following hardware and
software components:
Table 1-5: Components used

Component Qty. Article number Note
Power supply 1 6EP1332-4BA00 PM 190 W
SIMATIC S7 CPU 1 6ES7212-1AE40-0XB0 CPU 1212C DC/DC/DC
SIPLUS SM 1281 1 6AT8007-1AA10-0AA0 FW 2.0
Retro-reflective photoelectric 1 GLV18-55-G/73/120 Pepperl + Fuchs

sensor
Vibration sensor 1 6AT8002-4AB00 Sensitivity: 100.08 mV/g
SIMATIC HMI TP1200 Comfort 1 6AV2124-0MC01-0AX0 12"
SINAMICS V90 PN 1 6SL3210-5FB10-2UF0 Single-phase operation at 240 V
STEP 7 Basic 1 6ES7822-0AA03-0YA5 TIA Portal V13 SP1 Upd 6 or
higher
WinCC Advanced 1 6AV2102-0AA03-0AA5 TIA Portal V13 SP1 Upd 6 or
higher
HSP 0113 for the SM 1281 1 -- V2.0
For the download link, refer to
\5\.
Note The functionality was tested with the hardware components specified. Similar
products that are not included in the above list can also be used. In this case,
please note that changes to the example code (e. g. different addresses) may
become necessary.
This application example consists of the following components:
Table 1-6: Components of the application example

Component Note
109480750_CMS_S7-1200_RMS_DOC_V20_en.pdf This document
109480750_CMS_S7-1200_RMS_PROJ_TIAV13_V20.zip This zip file contains the project for TIA
Portal V13 SP1.
109480750_CMS_S7-1200_RMS_PROJ_TIAV14_V20.zip This zip file contains the project for TIA
Portal V14 SP1.

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2.1 Hardware setup
The figure below shows the hardware setup of the application.
Figure 2-1: Hardware setup

L+
L+ M L+ M
CPU 1214C SM 1281

VIB1 VIB2 VIB3 VIB4 RPM

PN IE + - + - + - + - P M IN
+ - +UB Ǭ 0 V Ǫ
Vibrations- Lichtschranke
sensor GLV18
Table 2-1: Installation

No. Action Remark
1. Place the CPU and the SM 1281 side by side
on a top hat rail.
2. Connect the two components using the
integrated bus.
3. Install the vibration sensor to the bearing Chapter 3.3.1 Measuring vibrations shows
pedestal of the shaft end. ways how to mount the sensor.

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No. Action Remark

4. Install the retro-reflective photoelectric sensor. Using a separate speed sensor is not
mandatory. You can also provide the speed to
the SM 1281 via the user program. The
function block “SM1281_Module” provides the
“SpeedSource” and “Speed” parameters for
this purpose.
5. Wire the components as shown in the
illustration above.
6. Switch on the power supply.
For this application example, the following IP addresses were used:
Table 2-2: IP addresses used

Component IP address Subnet mask
CPU 1212C 192.168.0.1 255.255.255.0
HMI TP1200 192.168.0.2 255.255.255.0
Web server SM 1281 192.168.0.200 255.255.255.0
SINAMICS V90 PN 192.168.0.3 255.255.255.0
Note You can specify the IP address of the web server of the SM 1281 at the
parameter "IPAddress" of the FB "SM1281_Module" or via the HMI (see chapter
2.4.2).
2.2 Configuration
The following instructions describe the procedure for TIA Portal V13 SP1, but also
applies to TIA Portal V14 and higher.
2.2.1 Preparation
1. Download the project file

“109480750_CMS_S7-1200_RMS_PROJ_TIAV13_V20.zip” at:
2. Save the zip file in any directory on your computer and extract it.
3. Download the HSP 0113 for the SM 1281. It is included in the HSP collection
for TIA Portal:
https://support.industry.siemens.com/cs/de/en/view/72341852
4. Save the zip file in any directory on your computer and extract it.
5. Set the IP address of the PG/PC in such a way that the PG/PC is located in the
same subnet as the CPU.
6. Use an Ethernet cable to connect the PG/PC with the Ethernet interface of the
CPU.

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2.2.2 Installing the HSP
1. Open “TIA Portal V13”.

2. Go to the project view.
3. In the menu bar, click “Options” > “Support Packages”.
4. Click "Add from file system" and select the HSP 0113 from the downloaded
HSP collection.
Figure 2-2: Adding an HSP

5. Select the HSP from the list and then click “Install”.
Figure 2-3: Installing the HSP
6. Follow the further instructions.

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2.2.3 Downloading the STEP 7 project into the CPU
1. In the menu bar in TIA Portal, click “Project > Open”.

2. Click “Browse” and open the extracted project.
3. Right-click “PLC_1 [CPU1212C DC/DC/DC]” in the project tree and then
“Download to device > Hardware and Software (only changes)”.
4. Select the corresponding interface and click “Start search”.
Figure 2-4
5. Select the CPU based on the IP or MAC address and then click “Load”.
Note The IP address and the device name are automatically assigned when
downloading the project into the CPU.

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Figure 2-5
6. Confirm the dialog by clicking “Load”. If the CPU is presently not in STOP, it
has to be stopped.
Figure 2-6
7. Tick the “Start all” check box and click “Finish”.

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2.2.4 Downloading the WinCC project into the HMI
1. Make sure that the HMI is in transfer mode or automatic transfer is allowed.
2. Right-click “TP1200 [TP1200 Comfort]” in the project tree and then “Download
to device > Hardware and Software (only changes)”.
3. Select the corresponding interface and click “Start search”.
4. Select the HMI based on the IP or MAC address and click “Load”.
Figure 2-7
8. Tick the “Overwrite all” check box and click “Load”.

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2.3 Commissioning
Below we will explain how you can determine limits for warnings and alarms for
your machine.
2.3.1 Measuring the normal operating condition of the machine
To detect wear and damages at the machine, we need to know the vibration
variables in the normal operating state. Therefore, the vibration variables are
measured during commissioning and are used as the basic values to calculate
warning and alarm limits.
Therefore, measure the vibration variables during commissioning and adjust the
warning and alarm limits correspondingly. A detailed instruction is given in chapter
2.4 Operation.
ATTENTIO If a bearing damage already exists during commissioning, this is not

N automatically detected by the CMS. Please observe the guide values given in
Table 2-3 to assess the condition of your machine during commissioning.
2.3.2 Determining the warning and alarm limits
We will show how to determine the warning and alarm limits using an example. The
machine in our example has the following properties:
 The motor capacity is 20 kW.
 The motor is mounted on a soft foundation.
The following guide values apply for this type of machines according to DIN ISO
10816-3:
Table 2-3: Guide values according to DIN ISO 10816-3

Assessed zones Vibration velocity
A Newly started up machine < 2.3 mm/s
B Machine in unlimited long-term operation < 4.5 mm/s
C Machine in short-term operation < 7.1 mm/s
D Vibrations cause damages > 7.1 mm/s

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Warning limit vRMS

The warning limit indicates that a significant change has occurred, but operation
can generally be continued. The reasons for the changed vibration condition
should be investigated and eliminated if necessary.
Recommendations from DIN ISO 10816-3:

If the increase (or decrease) of the vibration quantity exceeds 25 % of the upper
limit value of the corresponding zone B, the changes have to be considered
essential, in particular when they occur suddenly.
We therefore recommend setting the warning limit 25 % of the upper limit value of
the corresponding zone B higher than the basic value (the basic value is obtained
from past operational experiences at this measuring point). The limit should
generally not be higher than 1.25 times the upper limit of zone B.
As no experience values are available at the beginning, the value measured when
determining the normal operating state is used as the basic value. A basic value of
0.8 mm/s is measured for the machine in the example.
In this example, the warning limit is defined as follows:
𝑊𝑎𝑟𝑛𝑖𝑛𝑔 𝑙𝑖𝑚𝑖𝑡 𝑣𝑅𝑀𝑆 = 𝑏𝑎𝑠𝑖𝑐 𝑣𝑎𝑙𝑢𝑒 + 0.25 ∗ 𝑢𝑝𝑝𝑒𝑟 𝑙𝑖𝑚𝑖𝑡 𝑧𝑜𝑛𝑒 𝐵

𝑚𝑚 𝑚𝑚
𝑊𝑎𝑟𝑛𝑖𝑛𝑔 𝑙𝑖𝑚𝑖𝑡 𝑣𝑅𝑀𝑆 = 0.8 + (0.25 ∗ 4.5 )
𝑠 𝑠
𝒎𝒎
𝑾𝒂𝒓𝒏𝒊𝒏𝒈 𝒍𝒊𝒎𝒊𝒕 𝒗𝑹𝑴𝑺 = 𝟏. 𝟗𝟐𝟓
𝒔
Alarm limit vRMS

The intention of the alarm limit is to indicate that further operation may cause
machine damage. If this limit is exceeded, immediate measures should be taken to
reduce vibrations or the machine should be shut down.
Recommendations from DIN ISO 10816-3:
In general, the limit is located within the zones C or D. Generally, the limit should
not exceed 1.25 times the upper limit of zone C.
In this example, the upper limit of zone C is used as alarm limit:
𝒎𝒎
𝑨𝒍𝒂𝒓𝒎 𝒍𝒊𝒎𝒊𝒕 𝒗𝑹𝑴𝑺 = 𝟕. 𝟏
𝒔

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Warning limit aRMS

You can use the value of the aRMS vibration acceleration averaged over a
frequency range between 1 kHz and 10 kHz as bearing status monitoring.
The suggested warning and alarm limits are based on practical experiences. There
is no normative specification for limits.
To determine the warning limit, add 1 m/s² to the measured basic value in normal
operating condition of the machine.
A basic value of 0.8 m/s² is measured for the machine in the example.
𝑚
𝑊𝑎𝑟𝑛𝑖𝑛𝑔 𝑙𝑖𝑚𝑖𝑡 𝑎𝑅𝑀𝑆 = 𝑏𝑎𝑠𝑖𝑐 𝑣𝑎𝑙𝑢𝑒 + 1
𝑠2
𝒎
𝑾𝒂𝒓𝒏𝒊𝒏𝒈 𝒍𝒊𝒎𝒊𝒕 𝒂𝑹𝑴𝑺 = 𝟏. 𝟖
𝒔²
Alarm limit aRMS

To determine the alarm limit, add 2 m/s² to the measured basic value in normal
operating condition of the machine.
𝑚
𝐴𝑙𝑎𝑟𝑚 𝑙𝑖𝑚𝑖𝑡 𝑎𝑅𝑀𝑆 = 𝑏𝑎𝑠𝑖𝑐 𝑣𝑎𝑙𝑢𝑒 + 2 2
𝑠
𝒎
𝑨𝒍𝒂𝒓𝒎 𝒍𝒊𝒎𝒊𝒕 𝒂𝑹𝑴𝑺 = 𝟐. 𝟖
𝒔²
Now adjust the determined warning and alarm limits as shown in chapter 2.4.3.
Note In a real application, fixed warning and alarm limits are not sufficient for all
operating modes of a machine. For this, create e. g. an operating mode table
containing the warning and alarm limits depending on the speed and load in a
data block of the CPU.
Note Over time, the machine will undergo transient oscillations and the warning and
alarm limits should be adjusted.

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2.4 Operation
2.4.1 Notes on setting parameters
Static parameters
The parameters at the block interfaces are generally transmitted to the SM 1281
upon request only. All parameters at the input parameters of the blocks
“SM1281_Module” and “SM1281_Channel” are transmitted to the SM 1281 by a
positive edge at the input parameter “SetAllParameters”.
Depending on the current operating mode of the SM 1281, the operating mode is
changed automatically in the process. This is necessary, because some
parameters cannot be transferred into the SM 1281 in a RUN state. Following
successful transfer of the parameters to the SM 1281, the operating mode that was
active prior to the parameter transfer is restored.
If the parameters were not transferred successfully, an error message is generated
at the output parameter “OpModeChangeStatus” of the “SM1281_Module” block as
for a failed change of the operating mode and is displayed on the top right of each
screen.
Dynamic parameters
Besides the option to transmit all parameters to the SM 1281, you can also transfer
just the so-called dynamic parameters. The dynamic parameters at the input
parameters of the functions “SM1281_Channel” are transmitted to the SM 1281 by
a positive edge at the input parameter “SetDynParameters”.
These parameters can also be transmitted in the status “RUN: Monitoring” and
“RUN: INHIBITED" without the SM 1281 having to switch the operating mode into
stop mode.
The following are dynamic parameters:
Table 2-4: Dynamic parameters of the SM 1281

Parameter Description
AlarmLevel_vRMS Alarm limit of vibration velocity in mm/s
WarningLevel_vRMS Warning limit of vibration velocity in mm/s
AlarmLevel_aRMS Alarm limit of vibration acceleration in m/s²
WarningLevel_aRMS Warning limit of vibration acceleration in m/s²

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2.4.2 Setting the static parameters
1. On the start screen, tap the SM 1281 overview.
Figure 2-8: Overview

2. Tap the “Parameters” button.

3. Set the desired parameters.
Figure 2-9: “Parameters” screen
4. Tap the “Set All Parameters” button.

The SM 1281 switches to the “STOP: CONFIGURATION” mode and sets the
parameters. Subsequently, it changes back to the last operating mode.

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2.4.3 Setting dynamic parameters
1. Tap the “Parameters” button.

2. Set the desired parameters.
3. Tap the “Set Dynamic Parameters” button.
The SM 1281 switches to the “RUN: INHIBITED” mode and sets the
2.4.4 Changing the operating mode
The operating mode can be changed from any screen:

1. Tap the “ON” button.
Figure 2-10: Changing the operating mode

2. Select the desired operating mode from the drop-down list.
Figure 2-11: Selecting the operating mode
3. Tap "OK".
The operating mode is changed. The status is displayed in the text box below.

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2.4.5 Reading measured values
Tap the “Act. Values” button and read the measured values for the corresponding
channel.
Figure 2-12: Measured values vRMS and aRMS in case of the vRMS warning limit being
exceeded
Note The indicators of the spectra only show a status if frequency-selective monitoring
is activated in the SM 1281.

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2.4.6 Restoring parameters from the backup
With each successful transition to the “RUN: MONITORING” operating mode, the
parameters last sent to the SM 1281 are automatically checked for validity. If the
parameters are valid, they are backed up in the remanent data block
“SM1281_Backup”. If the parameters are invalid, an error message occurs in the
HMI and in the message system of the SM 1281 and the SM 1281 remains in the
operating mode "STOP: READY".
After a restart of the CPU or faulty parameterization, you can restore the saved
parameters.
1. Tap the “Backup” button.

2. Tap the “Restore Parameters” button.
Figure 2-13
The SM 1281 switches to the “STOP: CONFIGURATION” mode and sets the

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3 Valuable Information
3.1 Basic terms
CMS
CMS stands for Condition Monitoring System.
IEPE
IEPE stands for Integrated Electronics Piezo Electric. It is an industry standard for
piezoelectric sensors with built-in impedance converter electronics. They can be
sensors for acceleration, force and pressure.
RMS
RMS stands for Root Mean Square. In the quadratic mean, bigger values usually
have more impact than smaller ones in contrast to the geometric mean.
vRMS
Mean of the vibration velocity
aRMS
Mean of the vibration acceleration

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3.2 Mechanical vibrations

3.2.1 Meaning and significance of vibrations
Term
Mechanical vibrations can be felt and measured at the surface of bodies. When
monitoring machines, these are mainly machine surfaces, components and
foundations.
Mechanical vibrations are also referred to as structure-borne sound, as they
propagate in solid bodies only. The audible air-borne sound, in contrast,
propagates through gaseous media, e. g. air.
Generation of mechanical vibrations

Whenever masses move, mechanically vibrations occur, too. These masses can
be rotating or oscillating machine parts. However, these masses also include gases
or liquids that hit solid bodies.
The significance of vibrations

When monitoring machines, mechanical vibrations provide excellent information
as:
 Indicators of the machine condition

Indicators of dynamic stress of machines, foundations and adjacent machine

parts
 Indicators of the operational safety, service life and operating efficiency of
machines
 Basis of machine diagnosis and vibration damping
Running machines exhibit various symptoms that allow drawing conclusions to the
machine condition, e. g. looming machine damage.
These condition-relevant fault symptoms include:
 Changes in air-borne noise
 Displacement of machine parts
 Increased bearing temperatures
 Changed mechanical vibration behavior

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3.2.2 Causes of mechanical vibrations
Generation of vibrations
Vibrations are caused mainly by centrifugal forces at rotating machine parts.
This is caused, for example, by:
 Unbalance
 Improper alignment of machine trains
 Bearing-related damage
 Transmission faults
 Magnetic, hydraulic and/or other function-related changing forces
Transmission and intensity of vibrations

Dynamic forces cause the rotor and rotor shaft to oscillate. These oscillations are
transmitted through the bearings, for example. Transmission takes the following
route:
1. From moving to fixed machine components
2. From fixed machine components to the foundation
The intensity of the transmitted oscillations depends on these parameters among

others:
 Stiffness and dampening of the:

– Machine construction
– Bearing construction
– Foundation
 Condition of the bearing lubricant
 Decoupling of the foundation
 Ratio of the masses of machine and foundation

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3.3 Monitoring and diagnosing vibrations

To monitor a machine effectively during operation, specific variables have to be
recorded. Mechanical oscillations are crucial in this context, because they are
highly significant.
3.3.1 Measuring vibrations
Vibration sensor
Piezoelectric vibration sensors are used for the frequencies and frequency ranges
to be covered in the vibration monitoring solution with SM 1281. These sensors
generate an analog voltage signal in the presence of dynamic pressure and
traction forces that can be processed. Static acceleration forces such as the
gravitational acceleration are not detected by these sensors. IEPE (Integrated
Electronics Piezo-Electric) is an industry standard for piezoelectric sensors.
The figure below shows the frequency response of a vibration sensor.
Figure 3-1: Typical frequency response


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Selecting the measuring point

Below, you will find some general notes on positioning the vibration sensor:
Table 3-1: Measuring points

Description Display
1. For an optimum measuring result, the sensor's
measuring axis should be aligned in load
direction if possible.
2. The measuring distance between machine

bearing and measuring point should be as short
and straightforward as possible. Observe the
following notes in this context:
 Vibration signals decrease with increasing
signal path.
 Transitions between materials dampen
and/or reflect the signal to be measured.
3. Freely vibrating or elastically deformable

housing or cladding parts (e. g. fan lid) are no
suitable measuring points.

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Attachment to the object being measured

How the sensor is attached will considerably influence the measuring accuracy.
Good signal quality requires smooth and clean coupling faces. Paint on coupling
faces will also impair the result.
Below we will describe some common types of fasteners for vibration sensors:
Table 3-2: Attachment types

Attachment type Suitability Upper frequency
limit
Direct screwed For even and smooth 10 kHz to 20 kHz
connection using surfaces
threaded bolts
Screwed connection For uneven and/or 10 kHz to 20 kHz

using an painted areas
intermediate
adapter
Glued connection Depends on the 10 kHz to 18 kHz

using e. g. instant temperature

glue or epoxy resin properties of the glue
used
Attachment using For fast and flexible 5 kHz to 15 kHz

permanent magnets attachment
Suitability depends
on the adhesive
force, decreases at
higher frequencies

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Measured variables, frequencies and energy

Vibration sensors provide a continuous vibration acceleration time signal (red line
in Figure 3-2).
Low-frequency vibrations, i. e. vibrations associated with rotation, are the most
energy-rich.
Now, if we take into account that the area below the red line corresponds to the
vibration's energy content, it becomes clear that the evaluation of the vibration
velocity is preferable for low-frequency oscillations.
For this purpose, the sensor signal is integrated which – depending on the energy
content of the vibrations – results in the blue line shown in Figure 3-2.
Figure 3-2: Vibration velocity and acceleration

Further information
Further information on appropriate sensors and on selecting the measuring point
can be found in this FAQ:
3.3.2 Overview of diagnostic procedures
There are different methods and procedures to monitor and diagnose the condition
of machines.
The procedures for signal processing of vibration data for machine and bearing
diagnosis are divided into two main groups:
1. Characteristic values: summation of vibration data
2. Frequency-selective: evaluation of vibration data in the frequency spectrum

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3.3.3 Vibration diagnosis by measuring characteristic values in the time

domain
Application scope of vibration measurement in the time domain

Broadband vibration measurements in the time domain allow conclusions to be
drawn as to the overall machine condition and the effectiveness of measures to
suppress vibration.
The development of the machine condition can be verified by comparing actual
measurements with previous vibration levels or with published guiding values or
manufacturer specifications. This trend analysis enables degradations of the
machine condition to be detected at an early stage and the corresponding
countermeasures to be planned and implemented.
Note Detailed fault diagnosis is not possible or subject to restrictions for wideband
vibration measurement based on characteristic values.
Features of vibration measurements in the time domain

 The measurement methods and the assessment of wideband vibration
measurements are laid down and standardized in national and international
guidelines and standards.
 The values of the RMS vibration velocity are measured and averaged over a
defined frequency range.
 The range includes the frequencies from 2 Hz or 10 Hz to 1 kHz. Based on the
velocity, the measuring range according to ISO 10816 starts either at 2 Hz
(speeds from 120 to 600 rpm) or at 10 Hz (speeds greater than or equal to
600 rpm).
Fault types and diagnosis

The following table gives an overview of the most common fault types with the
suitable measuring variables (marked with an x) in order to recognize these.
Table 3-3: Fault types

Fault type Vibration measurement in the time domain
Vibration velocity vRMS Vibration acceleration
aRMS
Unbalance x --
Alignment fault, coupling x --
fault
Incorrect setup x --
Blade pass frequency fBP ≤ 1 kHz fBP > 1 kHz
Meshing fault fM ≤ 1 kHz fM > 1 kHz
Belt fault fb ≤ 1 kHz fb > 1 kHz
Resonances x --
Electric stator fault x --
Electric rotor fault x --
Bearing-related damage -- x

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Trend monitoring of the measured variables

The following chart depicts the typical shape of a trend curve by
measuring/determining characteristic values. Signs of a looming fault usually
manifest themselves long before the actual failure, e. g. by the increase of a
vibration quantity.
Figure 3-3: Trend monitoring

Table 3-4: Explanation of the trend monitoring

Explanations on the chart
1. During the run-in period of a new machine, the characteristic values are slightly
elevated at first. Afterwards, they decline to values that correspond to the
machine's normal operating state.
DIN ISO 10816-3 provides guide values for different types of machines.
2. The maintenance strategy may provide for scheduled maintenance. Regular
condition monitoring allows a looming damage to be detected in its early stage.
3. The characteristic value has exceeded a warning limit. The machine has to be
repaired. But the machine can still be used. Additional measurements show a
sharp increase of the characteristic values. Based on the trend it can be
extrapolated when a capital damage with machine outage would occur.
4. The defined alarm limit is exceeded. The machine is now repaired. Characteristic
value measurements show that the machine is back in its normal operating
condition.

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Evaluating the machine condition using RMS values

The RMS value of the vibration velocity is a wideband vibration value. It is
calculated by arithmetic averaging of all vibration events in a defined frequency
range (e. g. 10 Hz to 1 kHz at RMS vibration velocity).
Table 3-5: RMS values

Characteristic value Frequency range Monitoring possible
vRMS 2 or 10 Hz to 1 kHz Speed-related damages
Root Mean Square

(velocity)
aRMS > 1 kHz Bearing-related damage
Root Mean Square

(acceleration)
In the vibration frequency between 2 Hz or 10 Hz and 1 kHz, the RMS value of the
vibration velocity is the most meaningful analysis value. This frequency range
accommodates the typical rotation frequency excitations.
3.3.4 Vibration diagnosis through frequency analysis
Measuring the parameters is insufficient to pinpoint the fault. For this purpose, the
machine's vibration profile needs to be analyzed in more detail. Most types of
damages can be recognized in the frequency spectrum due to the occurrence of
typical damage frequencies or typical patterns of damage frequencies. The
SM 1281 allows the following spectra to be calculated and used for vibration
diagnosis and monitoring:
 Frequency spectrum of vibration velocity
 Frequency spectrum of vibration acceleration
 Envelope spectrum
As this application example covers the diagnosis by measuring characteristic

values in the time domain, we will not cover the diagnosis based on frequency
analysis in further detail. For more information on vibration diagnosis through
frequency analysis, refer to the SM 1281 manual at:

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3.3.5 Standards
As a rule, the following standards and guidelines are used for machine monitoring
using wideband characteristic values:
Table 3-6: Standards

Title Content Notes
EN 60034-14 Vibration measurement, Axle height ≥ 56 mm, rated
acceptance measurements in the output ≤ 50 MW, nrated: 120 to
manufacturing factory 15,000 1/min)
DIN ISO 10816-1 Vibration measurement, Parameter: RMS vibration
and -3 assessment at the installation site velocity (referred to as vRMS for
SIPLUS SM 1281)
3.4 SIPLUS SM 1281

The following chapter gives a brief overview of the SM 1281 with regard to the
functions used in this application example.
For the operating manual of the SIPLUS SM 1281, refer to the Industry Online
Support:
Overview
The SIPLUS SM 1281 is a module designed for use with the SIMATIC S7-1200
automation system.
SIPLUS SM 1281 allows the condition of components liable to wear (e. g. motors,
bearings) and of critical machine components to be monitored permanently.
Together with an S7-1200, it can be used as an autonomous monitoring system.
Technical features
 4 vibration sensor channels for vibration signal monitoring
 1 digital input for speed measurement
 Direct integration into existing SIMATIC S7-1200 automation systems
 Easy integration into existing and new machines
 High sampling rates
 Vibration analysis within the SM 1281. The result of the analysis is transmitted
to the S7-1200 CPU for processing via the backplane bus in the form of status
signals.
 Processing the results of the vibration analysis in the user's control program
 Configuration of SM 1281 functions directly from the TIA Portal

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Configuration
The figure below shows an example configuration using an SM 1281 together with
a SIMATIC S7-1200 automation system.
Figure 3-4: Exemplary setup

3.5 Library "SM1281_Library"

The library “SM1281_Library” of the SM 1281 signal module was used for this
application example. It contains STEP 7 blocks and HMI text lists. The library
enables the functions of the SM 1281 module to be integrated easily into the user's
control program.
The STEP 7 blocks from the “SM1281_Library” enable the SM 1281 modules
configured in the TIA Portal device configuration to be parameterized, controlled
and diagnosed.
The library blocks provide the following functions:

 Parameterization of the SM 1281 modules
 Output of status and traffic light information
 Switching of operating modes
 Requesting fingerprint and raw data recording
 Output of status information on the recording
 Automatic backup of valid parameter records
Depending on which CPU is used, the blocks allow integrating up to seven

SM 1281 modules into the control program.

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3.5.1 Overview
The SM 1281 module features module- and channel-specific settings and

diagnostic information. The module-specific settings and diagnostic information
include e. g. the IP configuration and the selection of and feedback on the current
operating mode. The channel-specific settings and diagnostic information refer to
the four vibration channels of the SM 1281 module to which vibration sensors for
machine monitoring can be connected.
Table 3-7: Components of the library

Type Symbolic name
Function block SM1281_Module
Function SM1281_Channel
Global data block SM1281_Status
Global data block SM1281_Backup
Note The blocks “SM1281_Module” and “SM1281_Channel” contained in the library

are mandatory to operate the SM 1281 module. Without these blocks,
parameterization and status monitoring is not possible. The parameters that can
be set using the blocks cannot be changed using the web server of the SM 1281
module.
The following chapters give an overview of the blocks' functionality. You will find
the library in SIOS:
For a detailed description of the parameters, see the SM 1281 operating
instructions:
3.5.2 Function block "SM1281_Module"
The function block “SM1281_Module” from the library enables all general module
settings to be entered and module status messages to be monitored.
The “SM1281_Module” block offers the following functions:

 IP configuration of the SM 1281 module
 Speed configuration
 Transmitting module and channel parameters to the SM 1281 module
 Requesting fingerprint and raw data recording
 Restoring the parameter record
 Selecting the operating mode of the SM 1281 module
 Output of module status and error information

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3.5.3 Function “SM1281_Channel”
The function “SM1281_Channel” can be assigned to a channel of the SM 1281

module and enables the parameterization and monitoring of the corresponding
vibration channel.
“SM1281_Channel” offers the following functions:

 Making channel-specific parameter settings
 Output of channel-specific status and error information
Basically, the function “SM1281_Channel” needs to be invoked for each used

channel of the SM 1281 module. The assignment to the corresponding channel is
made using the “ChannelNR” input parameter.
3.5.4 Data block "SM1281_Status"
The global data block “SM1281_Status” contains all information with regard to
status, traffic light and faults of the SM 1281 module. The data are organized by
module and channel. The data for an SM 1281 module are preset in the data block.
When using more than one SM 1281 module, the parameter “Module1” (PLC data
type “SM1281_ModuleStatus”) can be copied and inserted e. g. as “Module2”.
Moreover, you can rename the parameters “Module”, “Channel_1”, “Channel_2”,

“Channel_3” and “Channel_4” as desired.
3.5.5 Data block "SM1281_Backup"
The global data block “SM1281_Backup” stores the automatic backup of valid
parameter records.
With each successful transition to the “RUN: MONITORING” operating mode, the
parameters last sent to the SM 1281 are automatically checked for validity. If the
parameters are valid, they are backed up in the remanent data block
“SM1281_Backup”. If the parameters are invalid, an error message occurs in the
message system of the SM 1281 and the SM 1281 remains in the operating mode
"STOP: READY".
The last valid and transferred parameter record can be restored using the input
parameter “RestoreParameters” of the block “SM1281_Module”.
3.5.6 Data types
Data types which are part of the block library carry the prefix “SM1281” in their
name.
ATTENTIO If you change these data types, it may no longer be possible to compile your
N project due to the know-how protection of the library blocks. Therefore, leave
these data types unchanged.

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4 Appendix
4 Appendix
4.1 Service & support
Industry Online Support
Do you have any questions or need support?
Siemens Industry Online Support offers access to our entire service and support
know-how as well as to our services.
Siemens Industry Online Support is the central address for information on our
products, solutions and services.
Product information, manuals, downloads, FAQs and application examples – all
information is accessible with just a few mouse clicks at
https://support.industry.siemens.com
Technical Support
Siemens Industry's Technical Support offers quick and competent support
regarding all technical queries with numerous tailor-made offers
– from basic support right up to individual support contracts.
Please address your requests to the Technical Support via the web form:
www.siemens.com/industry/supportrequest
Service offer
Our service offer comprises, among other things, the following services:
 Product Training
 Plant Data Services
 Spare Parts Services
 Repair Services
 Field & Maintenance Services
 Retrofit & Modernization Services
 Service Programs & Agreements
Detailed information on our service offer is available in the Service Catalog:
https://support.industry.siemens.com/cs/sc
Industry Online Support app

Thanks to the "Siemens Industry Online Support" app, you will get optimum
support even when you are on the move. The app is available for Apple iOS,
Android and Windows Phone.
https://support.industry.siemens.com/cs/ww/en/sc/2067

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4 Appendix
4.2 Links and literature

Table 4-1: Links and literature
Topic
\1\ Siemens Industry Online Support
https://support.industry.siemens.com
\2\ Download page of this entry
\3\ Operating instructions SM 1281
\4\ STEP 7 Library SM 1281
\5\ Support packages for the hardware catalog in TIA Portal
4.3 Change documentation

Table 4-2: Change documentation
Version Date Modifications

V1.0 02/2016 First version
V2.0 10/2017 Adaptation of application example SM 1281 FW 2.0

Entry ID: 109480750, V2.0, 10/2017 41

Siemens Vibration Guidelines Monitoring

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Monitoring of

Warranty and liability

deficiency or breach of a condition which goes to the root of the contract

Monitoring of Vibration Variables with SM 1281

Warranty and liability ................................................................................................... 2

2.4.1 Notes on setting parameters .............................................................. 21

Monitoring of Vibration Variables with SM 1281

In order to monitor mechanical components, SIEMENS provides the SIPLUS CMS

After a prolonged period of uninterrupted operation, the documented trend curves

Topics not covered by this application

Monitoring of Vibration Variables with SM 1281

1.2 Mode of operation

Figure 1-1: Overview of components

Table 1-1: Legend for Figure 1-1

Monitoring of Vibration Variables with SM 1281

Figure 1-2: Vibration sensor

1.2.2 Monitoring mode

In monitoring mode, all variables to be monitored are measured, calculated and

Monitoring of Vibration Variables with SM 1281

Monitoring of Vibration Variables with SM 1281

1.2.3 Program overview

Figure 1-3: Program overview

Monitoring of Vibration Variables with SM 1281

Table 1-2: Explanation of the blocks

Monitoring of Vibration Variables with SM 1281

Table 1-3: Explanation of the screens

Table 1-4: Explanation of the faceplates

Monitoring of Vibration Variables with SM 1281

1.3 Components used

Table 1-5: Components used

Retro-reflective photoelectric 1 GLV18-55-G/73/120 Pepperl + Fuchs

This application example consists of the following components:

Table 1-6: Components of the application example

Monitoring of Vibration Variables with SM 1281

Figure 2-1: Hardware setup

CPU 1214C SM 1281

VIB1 VIB2 VIB3 VIB4 RPM

Table 2-1: Installation

Monitoring of Vibration Variables with SM 1281

No. Action Remark

For this application example, the following IP addresses were used:

Table 2-2: IP addresses used

1. Download the project file

Monitoring of Vibration Variables with SM 1281

2.2.2 Installing the HSP

1. Open “TIA Portal V13”.

Figure 2-2: Adding an HSP

Figure 2-3: Installing the HSP

6. Follow the further instructions.

Monitoring of Vibration Variables with SM 1281

2.2.3 Downloading the STEP 7 project into the CPU

1. In the menu bar in TIA Portal, click “Project > Open”.

Monitoring of Vibration Variables with SM 1281

7. Tick the “Start all” check box and click “Finish”.

Monitoring of Vibration Variables with SM 1281

2.2.4 Downloading the WinCC project into the HMI

8. Tick the “Overwrite all” check box and click “Load”.

Monitoring of Vibration Variables with SM 1281

2.3.1 Measuring the normal operating condition of the machine

ATTENTIO If a bearing damage already exists during commissioning, this is not

2.3.2 Determining the warning and alarm limits

Table 2-3: Guide values according to DIN ISO 10816-3

Monitoring of Vibration Variables with SM 1281